USRE40419E1 - Production of synthetic transportation fuels from carbonaceous material using self-sustained hydro-gasification - Google Patents

Production of synthetic transportation fuels from carbonaceous material using self-sustained hydro-gasification Download PDF

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USRE40419E1
USRE40419E1 US11/805,576 US80557603A USRE40419E US RE40419 E1 USRE40419 E1 US RE40419E1 US 80557603 A US80557603 A US 80557603A US RE40419 E USRE40419 E US RE40419E
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hydrogen
steam
hydro
fischer
reactor
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Joseph M. Norbeck
Colin E. Hackett
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University of California
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    • C01B3/02—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen
    • C01B3/32—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen by reaction of gaseous or liquid organic compounds with gasifying agents, e.g. water, carbon dioxide, air
    • C01B3/34—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen by reaction of gaseous or liquid organic compounds with gasifying agents, e.g. water, carbon dioxide, air by reaction of hydrocarbons with gasifying agents
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    • C10G1/00—Production of liquid hydrocarbon mixtures from oil-shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal
    • C10G1/002—Production of liquid hydrocarbon mixtures from oil-shale, oil-sand, or non-melting solid carbonaceous or similar materials, e.g. wood, coal in combination with oil conversion- or refining processes
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    • C10J2300/12—Heating the gasifier
    • C10J2300/1253—Heating the gasifier by injecting hot gas
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J2300/00—Details of gasification processes
    • C10J2300/16—Integration of gasification processes with another plant or parts within the plant
    • C10J2300/164—Integration of gasification processes with another plant or parts within the plant with conversion of synthesis gas
    • C10J2300/1643—Conversion of synthesis gas to energy
    • C10J2300/165—Conversion of synthesis gas to energy integrated with a gas turbine or gas motor
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J2300/00—Details of gasification processes
    • C10J2300/16—Integration of gasification processes with another plant or parts within the plant
    • C10J2300/164—Integration of gasification processes with another plant or parts within the plant with conversion of synthesis gas
    • C10J2300/1656—Conversion of synthesis gas to chemicals
    • C10J2300/1659—Conversion of synthesis gas to chemicals to liquid hydrocarbons
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J2300/00—Details of gasification processes
    • C10J2300/16—Integration of gasification processes with another plant or parts within the plant
    • C10J2300/1671—Integration of gasification processes with another plant or parts within the plant with the production of electricity
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J2300/00—Details of gasification processes
    • C10J2300/16—Integration of gasification processes with another plant or parts within the plant
    • C10J2300/1671—Integration of gasification processes with another plant or parts within the plant with the production of electricity
    • C10J2300/1675—Integration of gasification processes with another plant or parts within the plant with the production of electricity making use of a steam turbine
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J2300/00—Details of gasification processes
    • C10J2300/16—Integration of gasification processes with another plant or parts within the plant
    • C10J2300/1693—Integration of gasification processes with another plant or parts within the plant with storage facilities for intermediate, feed and/or product
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J2300/00—Details of gasification processes
    • C10J2300/18—Details of the gasification process, e.g. loops, autothermal operation
    • C10J2300/1807—Recycle loops, e.g. gas, solids, heating medium, water
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J2300/00—Details of gasification processes
    • C10J2300/18—Details of the gasification process, e.g. loops, autothermal operation
    • C10J2300/1853—Steam reforming, i.e. injection of steam only
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J2300/00—Details of gasification processes
    • C10J2300/18—Details of the gasification process, e.g. loops, autothermal operation
    • C10J2300/1861—Heat exchange between at least two process streams
    • C10J2300/1884—Heat exchange between at least two process streams with one stream being synthesis gas
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
    • C10J2300/00—Details of gasification processes
    • C10J2300/18—Details of the gasification process, e.g. loops, autothermal operation
    • C10J2300/1861—Heat exchange between at least two process streams
    • C10J2300/1892—Heat exchange between at least two process streams with one stream being water/steam
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E20/00—Combustion technologies with mitigation potential
    • Y02E20/16—Combined cycle power plant [CCPP], or combined cycle gas turbine [CCGT]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E50/00—Technologies for the production of fuel of non-fossil origin
    • Y02E50/30—Fuel from waste, e.g. synthetic alcohol or diesel
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P20/00—Technologies relating to chemical industry
    • Y02P20/141—Feedstock
    • Y02P20/145—Feedstock the feedstock being materials of biological origin
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P20/00—Technologies relating to chemical industry
    • Y02P20/50—Improvements relating to the production of bulk chemicals
    • Y02P20/52—Improvements relating to the production of bulk chemicals using catalysts, e.g. selective catalysts

Definitions

  • This invention was made with support from the City of Riverside.
  • the City of Riverside has certain tights to this invention.
  • the field of the invention is the synthesis of transportation fuel from carbonaceous feed stocks.
  • Liquid transportation fuels have inherent advantages over gaseous fuels, having higher energy densities than gaseous fuels at the same pressure and temperature. Liquid fuels can be stored at atmospheric or low pressures whereas to achieve liquid fuel energy densities, a gaseous fuel would have to be stored in a tank on a vehicle at high pressures that can be a safety concern in the case of leaks or sudden rupture. The distribution of liquid fuels is much easier than gaseous fuels, using simple pumps and pipelines. The liquid fueling infrastructure of the existing transportation sector ensures easy integration into the existing market of any production of clean-burning synthetic liquid transportation fuels.
  • Biomass material is the most commonly processed carbonaceous waste feed stock used to produce renewable fuels. Waste plastic, rubber, manure, crop residues, forestry, tree and grass cuttings and biosolids from waster water (sewage) treatment are also candidate feed stocks for conversion processes. Biomass feed stocks can be converted to produce electricity, heat, valuable chemicals or fuels. California tops the nation in the use and development of several biomass utilization technologies. Each year in California, more than 45 million tons of municipal solid waste is discarded for treatment by waste management facilities. Approximately half this waste ends up in landfills. For example, in just the Riverside County, California area, it is estimated that about 4000 tons of waste wood are disposed of per day. According to other estimates, over 100,000 tons of biomass per day are dumped into landfills in the Riverside County collection area.
  • This municipal waste comprises about 30% waste paper or cardboard, 40% organic (green and food) waste, and 30% combinations of wood, paper, plastic and metal waste.
  • the carbonaceous components of this waste material have chemical energy that could be used to reduce the need for other energy sources if it can be converted into a clean-burning fuel.
  • These waste sources of carbonaceous material are not the only sources available. While many existing carbonaceous waste materials, such as paper, can be sorted, reused and recycled, for other materials, the waste producer would not need to pay a tipping fee, if the waste were to be delivered directly to a conversion facility. A tipping fee, presently at $30-$35 per ton, is usually charged by the waste management agency to offset disposal costs. Consequently not only can disposal costs be reduced by transporting the waste to a waste-to-synthetic fuels processing plant, but additional waste would be made available because of the lowered cost of disposal.
  • An example of the latter process is the Hynol Methanol Process, which uses hydro-gasification and steam reformer reactors to synthesize methanol using a co-feed of solid carbonaceous materials and natural gas, and which has a demonstrated carbon conversion efficiency of >85% in bench-scale demonstrations.
  • the present invention makes use of steam pyrolysis, hydro-gasification and steam reformer reactors to produce a synthesis gas that can be converted into a synthetic paraffinic fuel, preferably a diesel fuel, although synthetic gasolines and jet propulsion fuels can also be made, using a Fischer-Tropsch paraffin fuel synthesis reactor.
  • the synthesis gas may be used in a co-generated power conversion and process heat system.
  • the present invention provides comprehensive equilibrium thermo-chemical analyses for a general class of co-production processes for the synthesis of clean-burning liquid transportation fuels, thermal process energy and electric power generation from feeds of coal, or other carbonaceous materials, and liquid water. It enables a unique design, efficiency of operation and comprehensive analysis of coal, or any other carbonaceous feed materials to co-produced fuel, power and heat systems.
  • the invention provides a process and apparatus for producing a synthesis gas for use as a gaseous fuel or as feed into a Fischer-Tropsch reactor to produce a liquid paraffinic fuel, recycled water and sensible heat, in a substantially self-sustaining process.
  • a slurry of particles of carbonaceous material suspended in liquid water, and hydrogen from an internal source are fed into a steam generator for pyrolysis and hydro-gasification reactor under conditions whereby super-heated steam, methane, carbon dioxide and carbon monoxide are generated and fed into a steam reformer under conditions whereby synthesis gas comprising primarily of hydrogen and carbon monoxide are generated.
  • a portion of the hydrogen generated by the steam reformed is fed into the hydro-gasification reactor as the hydrogen from an internal source.
  • the remaining synthesis gas generated by the steam reformer is either used as fuel for a gaseous fueled engine or gas turbine to produce electricity and process heat, or is fed into a Fischer-Tropsch fuel synthesis reactor under conditions to produce a liquid fuel, and recycled water.
  • the correct stoichiometric ratio of hydrogen to carbon monoxide molecules fed into the Fischer-Tropsch fuel synthesis reactor is controlled by the water to carbon ratio in the feed stocks.
  • Molten salt loops are used to transfer heat from the exothermic hydro-gasification reactor (and from the exothermic Fischer-Tropsch reactor if liquid fuel is produced) to the exothermic steam generator for pyrolysis and the steam reformer reactor vessels.
  • the present invention provides the following features.
  • a general purpose solid carbonaceous material feed system that can accept arbitrary combinations of coal, urban and agricultural biomass, and municipal solid waste for hydro-gasification.
  • a steam reformer as a second stage reactor to produce hydrogen rich synthesis gas from the output of the first stage steam generator for pyrolysis and hydro-gasification unit.
  • the molal steam to carbon ratio is maintained as necessary to bring the chemical reactions close to equilibrium;
  • thermo-chemical process reactors are operated to produce nearly pure paraffinic hydrocarbon liquids (similar to petroleum derived diesel fuels) and was-like compounds (similar to petroleum derived USP paraffinic jellies, which can be further refined into more diesel-like fuels using conventional methods) from carbonaceous feed stocks (such as waste wood) in a continuous self-sustainable fashion without the need for additional fuels or external energy sources.
  • the reactor configurations can also be optimized for the production of other synthetic fuels, such as dimethyl ether (a fuel similar to propane, that can be used as a transportation fuel in diesel engines and gas turbines) and gaseous fuel grade hydrogen (a fuel that can be used in engines and turbines, and if purified to remove carbon monoxide, as an electrochemical fuel in a fuel cell), as well as energetic synthesis gases for combined cycle power conversion and electric power production.
  • synthetic fuels such as dimethyl ether (a fuel similar to propane, that can be used as a transportation fuel in diesel engines and gas turbines) and gaseous fuel grade hydrogen (a fuel that can be used in engines and turbines, and if purified to remove carbon monoxide, as an electrochemical fuel in a fuel cell), as well as energetic synthesis gases for combined cycle power conversion and electric power production.
  • FIG. 1 is a flow diagram showing the overall modeling of the present invention
  • FIG. 2 is a graph showing a plot of carbon conversion vs. H 2 /C and H 2 O/C ratios at 800° C. and 30 atm. in HPR;
  • FIG. 3 is a graph showing a plot of CH 4 /C feed ratio vs. H 2 /C and H 2 O/C ratios at 800° C. and 30 atm. in HPR;
  • FIG. 4 is a graph showing a plot of CO 2 /C feed ratio vs. H 2 /C and H 2 O/C ratio sat 800° C. and 30 atm. in HPR;
  • FIG. 5 is a graph showing a plot of CO/C feed ratio vs. H 2 /C and H 2 O/C ratios at 800° C. and 30 atm. in HPR;
  • FIG. 6 is a graph showing the effects of Temperature and Pressure conditions on CO 2 /H ration the hydro-gasifier reactor (HGR) at fixed feed of 2.629 moles of H 2 and 0.0657 moles of H 2 O per mole of C;
  • FIG. 7 is a graph showing the effect of Temperature and Pressure conditions on CH 4 /H ratio in the HGR at fixed feed of 2.629 moles of H 2 and 0.0657 moles of H 2 O per mole of C;
  • FIG. 8 is a graph showing the effect of Temperature and Pressure conditions on H 2 /C ratio in the HGR at fixed feed of 2.629 moles of H 2 and 0.0657 moles of H 2 O per mole of C;
  • FIG. 9 is a graph showing the effect of Temperature and Pressure conditions on CO/H in the HGR at fixed feed of 2.629 moles of H 2 and 0.0657 moles of H 2 O per mole of C;
  • FIG. 10 is a graph showing the effect of input H 2 O/C ratio on steam reformer (SPR) performance measure by the net H 2 /CO ratio after H2 recycling for the HGR at 1000° C. and 30 atm;
  • FIG. 11 is a graph shown the effect of changing the input H 2 O/C ratio on SPR products, CO, CO 2 and CH 4 in the SPR at 1000° C. and 30 atm;
  • FIG. 12 is a graph showing the effect of Temperature and Pressure conditions on H 2 /CO ratio in the SPR (2.76 moles of H 2 O/mole of C added to the SPR);
  • FIG. 13 is a graph showing the effect of Temperature and Pressure conditions on CH 4 /C ratio in the SPR (2.76 moles of H 2 O/mole of C added to the SPR);
  • FIG. 14 is a diagram showing the Mass Flow Schematic of Biomass Hydro-gasification for production of Fischer-Tropsch paraffin fuels
  • FIG. 15 is a diagram showing the Molal Flow Schematic of Biomass Hydro-gasification for production of Fischer-Tropsch paraffin fuels
  • FIG. 16 is a diagram showing the Thermal Energy Management Schematic of Biomass Hydro-gasification for production of Fischer-Tropsch paraffin fuels
  • FIG. 17 is a diagram showing the Water/Steam Flow Schematic of Biomass Hydro-gasification for production of Fischer-Tropsch paraffin fuels
  • FIG. 18 is a diagram showing Molten Salt Flow Schematic of Biomass Hydro-gasification for production of Fischer-Tropsch paraffin fuels
  • FIG. 19 is a diagram showing Mass Flow Schematic of Biomass Hydro-gasification for production of dimethyl ether
  • FIG. 20 is a diagram showing Mole Flow Schematic of Biomass Hydro-gasification for production of dimethyl ether
  • FIG. 21 is a diagram showing Thermal Energy Management Schematic of Biomass Hydro-gasification for production of dimethyl ether
  • FIG. 22 is a diagram showing Water/Steam Flow Schematic of Biomass Hydro-gasification for production of dimethyl ether
  • FIG. 23 is a diagram showing Molten Salt Flow Schematic of Biomass Hydro-gasification for production of dimethyl ether
  • FIG. 24 is a diagram showing Mass Flow Schematic of Biomass Hydro-gasification for production of gaseous hydrogen fuel
  • FIG. 25 is a diagram showing Mole Flow Schematic of Biomass Hydro-gasification for production of gaseous hydrogen fuel
  • FIG. 26 is a diagram showing Thermal Energy Management Schematic of Biomass Hydro-gasification for production of gaseous hydrogen fuel
  • FIG. 27 is a diagram showing Water/Steam Flow Schematic of Biomass Hydro-gasification for production of gaseous hydrogen fuel
  • FIG. 28 is a diagram showing Molten Salt Flow Schematic of Biomass Hydro-gasification for production of gaseous hydrogen fuel
  • FIG. 29 is a diagram showing Mass Flow Schematic of Biomass Hydro-gasification for production of electricity
  • FIG. 30 is a diagram showing Mole Flow Schematic of Biomass Hydro-gasification for production of electricity
  • FIG. 31 is a diagram showing Thermal energy Management Schematic of Biomass Hydro-gasification for production of electricity
  • FIG. 32 is a diagram showing Water/Steam Flow Schematic of Biomass Hydro-gasification for production of electricity
  • FIG. 33 is a diagram showing Molten Salt Flow Schematic of Biomass Hydro-gasification for production of electricity
  • FIG. 34 is a mass flow schematic of biomass hydro-gasification for Fischer-Tropsch paraffin fuel production using an adiabatic HGR and a 9:1 water feed;
  • FIG. 35 is a molal flow schematic of biomass hydro-gasification for Fischer-Tropsch paraffin fuel production using an adiabatic HGR and a 9:1 water feed;
  • FIG. 36 is a thermal energy management schematic of biomass hydro-gasification for Fischer-Tropsch paraffin fuel production using an adiabatic HGR and a 9:1 water feed;
  • FIG. 37 is a water/steam flow schematic of biomass hydro-gasification for Fischer-Tropsch paraffin fuel production using an adiabatic HGR and a 9:1 water feed;
  • FIG. 38 is a molten salt flow schematic of biomass hydro-gasification for Fischer-Tropsch paraffin fuel production using an adiabatic HGR and a 9:1 water feed.
  • a steam generator for pyrolysis, hydro-gasification reactor (HGR) and steam pyrolytic reformer (SPR) may be utilized to produce the synthesis gas (syngas) through steam pyrolysis of the feed stock, hydro-gasification and steam reforming reactions.
  • the reactions start in the HGR to convert carbon in the carbonaceous matter into a methane rich producer gas and continue through the SPR to produce synthesis gas with the correct hydrogen and carbon monoxide stiochiometry for efficient operation of the Fischer-Tropsch process.
  • the Fischer-Tropsch process as the final step in processing, products such as synthetic gasoline, synthetic diesel fuel and recycled water can be produced.
  • the feedstock requirement is highly flexible. Many feeds that consist of different carbonaceous materials can be wet milled to form a water slurry that can be fed at high pressure into a steam pyrolyzer, hydro-gasifier and steam reformer reactors for synthesis gas production.
  • the feed to water mass ratio can even vary during the running of the process, with a knowledge of the chemical content of the feed, to maintain the carbon-hydrogen stiochiometry required for an optimized fuel synthesis process.
  • Appropriate carbonaceous materials include biomass, natural gas, oil, petroleum coke, coal, petrochemical and refinery by-products and wastes, plastics, tires, sewage sludge and other organic wastes.
  • wood is an example of waste biomass material that is readily available in Riverside County, California. This particular waste stream could be augmented with other carbonaceous materials, such as green waste and biosolids from water treatment that are available in Riverside County, and would otherwise go to landfill.
  • the process When used to make a transportation fuel, such as diesel fuel, the process is designed so that the feedstock makes the maximum amount of Fischer-Tropsch paraffinic product required.
  • the desired output consists of a liquid hydrocarbon, such as cetane, C 16 H 34 , within the carbon number range, 12 to 20, suitable as a diesel fuel.
  • Excess synthesis gas output from the SPR i.e., “leftover” chemical energy from the Fischer Tropsch synthetic fuel producing process, can be used as an energetic fuel to run a gas turbine for electricity production.
  • the synthesis gas output after recycling enough hydrogen to sustain the hydro-gasifier may be used for this purpose also, depending on the needs of the user.
  • the following provides a method for maximizing the economic potential from the present invention in the conversion of carbonaceous materials to a usable transportation fuels and inclusive of the possibility for direct electric power production through a gas turbine combined cycle.
  • thermo-chemical conversion of carbonaceous materials occurs by two main processes: hydro-gasification and steam reformation, with steam pyrolysis of the feedstock occurring within the steam generator to pre-treat feedstock and activate the carbon contained therein.
  • the hydro-gasifier requires an input of the pyrolyzed carbonaceous waste, hydrogen, steam, reacting in a vessel at high temperature and pressure, which in a specific implementation is approximately 30 atmospheres and 1000 degrees Celsius.
  • Steam reforming of the methane rich effluent gas from the HGR also requires an approximate pressure of 30 atmospheres and 1000 degrees Celsius. More generally, each process can be conducted over a temperature range of about 700 to 1200 degrees Celsius and a pressure of about 20 to 50 atmospheres. Lower temperatures and pressures can produce useful reaction rates with the use of appropriate reaction catalysts.
  • FIG. 1 is an overall flow diagram, the order of general processes that carry out these main reaction processes is shown (specific amounts for a particular embodiment are in the flow diagrams shown in FIGS. 14 through 38 ). Piping is used to convey the materials through the process.
  • the feed 11 is chopped, milled or ground in a grinder 10 into small particles, mixed with the recycled water 12 and placed in a receptacle or tank 14 as a liquid, suspension slurry 16 that is transportable as a compressed fluid by a pump 18 to a steam generator 20 where the slurry 16 is superheated and pyrolyzed, followed by either separation of the steam in a steam separator 22 so that steam goes through piping 24 that is separate from piping that delivers the pumped, dense slurry paste 26 , or a direct steam pyrolysis feed through piping 27 .
  • the dense slurry paste feed 26 enters the HGR 28 .
  • Hydrogen from an internal source from the steam reformer via a hydrogen separation filter described below
  • the output gases consists largely of methane, hydrogen, carbon monoxide, and super-heated steam.
  • the gases produced by the HGR 28 leaves the chamber and is pumped over to the SPR 30 .
  • the un-reacted residue (or ash) from the HGR is periodically removed from the bottom of the reactor vessel using a double buffered lock-hopper arrangement, that is commonly used in comparable high pressure gasification systems.
  • the ash is expected to be comprised of sand, SiO 2 , and alumina, Al 2 O 3 , with trace amounts of metals.
  • the input to the SPR 30 is delivered from either the steam separator 22 by piping 32 through a heater 34 and further piping 36 , or via the HGR 28 output piping, to provide greater-than-theoretical steam to carbon ratio into the SPR 30 , to mitigate coking in the reactor.
  • the output is a higher amount of hydrogen, and CO, with the appropriate stiochiometry for the desired hydrocarbon fuel synthesis process described below.
  • the output of the SPR 30 is directed via piping 38 through heat exchangers 40 and 42 .
  • Condensed water 44 is separated and removed from the SPR output, via a heat exchanger and liquid water expander 47 .
  • the non-condensable gaseous output of SPR 30 is then conveyed to a hydrogen separation filter 46 .
  • a portion of the hydrogen from the SPR output, about one-half in this embodiment, is carried from the filter 46 , passed through the heat exchanger 40 with a resultant rise in its temperature (in the embodiment from 220 degrees centigrade to 970 degrees Centigrade) and delivered to the HGR 28 as its hydrogen input.
  • the hot effluent from the SPR output is cooled by passing through heat exchangers 40 and 42 , used to heat the recycled hydrogen, and make steam respectively.
  • the condensed water 44 leaving the heat exchanger 47 is recycled back to make the water supply 12 for the slurry feed.
  • the fuel synthesis gas is then used for one of two options. Based on the calorific value, the synthesis gas may go through a gas turbine combined cycle for direct energy production or through a fuel synthesis reactor (in this embodiment, a Fischer-Tropsch process to produce a clean diesel fuel and recycled water). In accordance with a specific embodiment of the invention, the synthesis gas is directed through an expansion turbine 48 , to recover mechanical energy by lowering the pressure of the gaseous feed into the Fischer-Tropsch reactor 50 .
  • the mechanical power produced by the liquid state turbine, the Brayton and Rankine cycle turbines can be used to provide power for internal slurry, water feed pumps, air compressor, with the surplus exported via electricity generation, see Tables 1 through 7.
  • Efficiency may be maximized by adjusting input and process parameters.
  • the biomass/coal varying-mixture feed is synthesized into a slurry by adding water whereby after steam separation the carbon to hydrogen ratio will be appropriate for the process.
  • a slurry feed needs enough water to run the hydro-gasifier, the steam reformer, and to keep the feed in a viable slurry after steam separation.
  • Prior art attempts at biomass conversion using solid dry feed had many mechanical problems of feeding a solid into the high pressure, and high temperature HGR reaction chamber. This method of slurry feed has already been demonstrated and studied, according to the results for the “Hydrothermal Treatment of Municipal Solid Waste to Form High Solids Slurries in a Pilot Scale System”, by C. B.
  • the main purpose of the HGR process is to maximize the carbon conversion from the feed stock into the energetic gases CH 4 and CO.
  • hydrogen is produced by reacting superheated steam with CH 4 and CO within the SPR.
  • half the hydrogen is obtained from the superheated steam and the remainder from the CH 4 .
  • the principle reactions in the SPR are considered to be: CH 4 +H 2 O ⁇ CO+3H 2 (4) CO 2 +H 2 ⁇ CO+H 2 O ⁇ CO 2 +H 2 (5)
  • the steam reforming reactions (4 and 5) are often run with steam concentrations higher than required for the stiochiometry shown above. This is done to avoid coke formation and to improve conversion efficiency.
  • the required steam concentration is usually specified in the form of the steam-to-carbon mole ratio (S:C), the ratio of water steam molecules per carbon atom in the HGR feed.
  • S:C steam-to-carbon mole ratio
  • the preferred (S:C) ratio for the SPR operation is greater than 3.
  • This steam rich condition favors the water-gas shift reaction.
  • the present invention using the Fischer-Tropsch process can produce a zero-sulfur, ultrahigh cetane value diesel-like fuel and valuable paraffin wax products.
  • the absence of sulfur enables low pollutant and particle emitting diesel fuels to be realized.
  • the Fischer-Tropsch reactions also produce tail gas that contains hydrogen, CO, CO 2 , and some light hydrocarbon gases. Hydrogen can be stripped out of the tail gas and recycled either to the HGR or the Fischer-Tropsch reactor. Any small amounts of other gases such as CO and CO 2 may be flared off.
  • Fischer-Tropsch Two main products of Fischer-Tropsch may be characterized as synthetic oil and petroleum wax. According to Rentech, in the above report for their particular implementation of the Fischer-Tropsch process, the mix of solid wax to liquid ratio is about 50/50. Fischer-Tropsch products are totally free of sulfur, nitrogen, nickel, vanadium, asphaltenes, and aromatics that are typically found in crude oil. The products are almost exclusively paraffins and olefins with very few, or no, complex cyclic hydrocarbons or oxygenates that would otherwise require further separation and/or processing in order to be usable end-products. The absence of sulfur, nitrogen, and aromatics substantially reduces harmful emissions.
  • California's Air Resources Board (CARB) specifications for diesel fuel require a minimum cetane value of 48 and reduced sulfur content.
  • the above Rentech study with Shell diesel flue produced from a Fischer-Tropsch process has a cetane value of 76.
  • the CARB standard for sulfur in diesel fuel placed in the vehicle tank is 500 ppm by weight, and Shell's Fischer-Tropsch process diesel fuel has no detectable amount in the ppm range.
  • the CARB standard for aromatic content is no more than 10% by volume (20% for small refineries).
  • the Shell Fischer-Tropsch process diesel fuel had no detectable aromatics.
  • a gas turbine combined cycle for electric power production is an option. If the Fischer-Tropsch product is unexpectedly too costly, the use of the synthesis gas heating value can be a viable option, based on an overall efficiency of 65% of the synthesis gas energy converting to electric energy. This number is reasonable since the synthesis gas starts at a high temperature as opposed to taking natural gas in from a pipeline.
  • Process modeling can be used to reasonably produce a synthesis gas maximized for a yield high in CO and stoichiometric hydrogen.
  • the unit operation reactions of the hydro-gasifier, steam reformer, and Fischer-Tropsch reactors are modeled. This may be accomplished by using Stanjan, a DOS-based computer program that uses equilibrium modeling.
  • Stanjan a DOS-based computer program that uses equilibrium modeling.
  • the hydro-gasifier variables were modified for the maximum practical carbon conversion efficiency.
  • the steam reformer variables were modified for maximum practical CO output, enough hydrogen for recycling output, and minimum CO 2 production.
  • FIG. 5 shows the effect of H 2 and H 2 O on CO in the HGR at 800° C. and 30 atm.
  • FIGS. 6 , 7 , 8 and 9 show the effects of varying temperature and pressure on the chemical composition of the effluent gases from the HGR at feed of 2.76 mol H 2 and 0.066 mol H 2 O per mole C in the feed stock.
  • the carbon conversion efficiency is estimated to close to 100% in a temperature range of 800 to 1000° C. and a pressure range of 30 atm. to 50 atm, for equilibrium chemistry.
  • FIG. 10 shows the ratio of H 2 and CO available for feed into the Fischer-Tropsch fuel synthesis reactor, against the steam content added to the SPR at 800° C. and 30 atm. This ratio increases with the increasing amount of steam added to the SPR and reaches 2.1 at about 3.94 mol steam (or water) added per mol C in feedstock. With this amount of steam added, the system will achieve chemical and thermal self-substantiality and provide a proper ratio of H 2 and CO for Fischer-Tropsch synthesis of cetane.
  • FIG. 11 shows the effect of H 2 O added to the SPR at 800° C. and 30 atm.
  • FIGS. 12 and 13 show the effect of temperature and pressure on the H 2 and CO ratio and the conversion of CH 4 in the SPR. At higher temperature and lower pressure, this ratio is higher. In a similar trend with the H 2 and CO ratio, the conversion of CH 4 increases with increasing temperature and with decreasing pressure. It is thus high temperature and low pressure favored in the SPR.
  • the products of Fischer-Tropsch paraffinic liquid fuels are in a wide range of carbon number. According to the above Rentech report, about half of the products are diesel fuel. Also about half of the products come in the form of wax, with minor amounts of gases such as un-reacted reactants and hydrocarbon gases (methane, ethane, propane and so forth). To exemplify the present invention, cetane, which is in middle position of diesel range (C 11 to C 20 ), was chosen as diesel fuel.
  • Tables 1 through 5 show the overall energy transfer rates into and out from each heat exchanger and power conversion component for each operating mode of the conversion process.
  • the mass flow, molal flow, thermal energy management, water/steam and molten slat schematic diagrams for each of the five operating modes of the conversion process are also shown as FIGS. 14-18 , 19 - 23 , 24 - 28 , 29 - 33 and 34 - 38 respectively.
  • Tables 6 and 7 summarize the results of the performance studies and process configuration parameters for each of the five operating modes of the conversion process.
  • the carbonaceous material feed process initially described above uses a water slurry suspension feed technology, originally developed by Texaco for use in its partial-oxidation gasifiers, that can accept a wide variety of carbonaceous materials, and can be metered by controlled pumping into the first stage hydrogen gasification reactor (HGR) to produce a methane rich gas with high conversion efficiency (measured to have at least 85% carbon feed chemical utilization efficiency). Enough heat is available to be able to generate super-heated steam from the biomass-water slurry feed to supply and operate the second stage steam-methane reformer.
  • the reformer product gas is fed into a hydrogen membrane filter that allows almost pure hydrogen to pass back into the first stage reactor to sustain the hydro-gasification of the biomass.
  • the remaining second stage product gas not passing through the hydrogen filter, is cooled to condense and re-cycle any water vapor present back into the slurry carbonaceous feed system.
  • the unfiltered gas is fed into the fuel synthesis reactors, which comprise a Fischer-Tropsch paraffin hydro-carbon synthesis reactor, which operates at 200° C. and 10 atmospheres pressure.
  • the fuel synthesis reactors comprise a Fischer-Tropsch paraffin hydro-carbon synthesis reactor, which operates at 200° C. and 10 atmospheres pressure.
  • Process modeling reveals that the hydrogen/carbon molecular feed ratio must be at least 2.1:1 to optimize production of chemically pure and clean-burning [sulfur-free] diesel-like liquid fuels and high value chemically pure paraffin-like waxes, without additional fuel or energy.
  • Fischer-Tropsch products 0.199 ton wax per ton of feedstock; 68.3 gallons of cetane (C 16 H 34 )diesel per ton of feedstock.
  • H2/C H2O/C CO/H2 CH4/CO HGR 1000 30 3.48 0.07 SPR 1000 30 2.47 4.15 0.21 0.93 synthesis reactor 200 10 1.4 0.47 0.03 overall energy utilization 50.7% 2 Dimethyl ether (DME) bbl/day # water fed needed 184387 4425 2.2 dimethyl ether produced 20045 481 4530 160.6 33.9% electricity exported 110.3 23.3% process water recovered 207334 4976 Input conditions: T deg. C. P atm.
  • H2/C H2O/C CO/H2 CH4/CO HGR 1000 30 3.48 0.07 SPR 1000 30 2.47 2.91 0.21 0.93 synthesis reactor 260 70 1.2 0.58 0.05 overall energy utilization 57.3% 3 Gaseous Hydrogen (GH2) cu m/day+ water fed needed 184387 4425 2.2 gaseous hydrogen (GH2) 5618 135 1899 221.4 46.8% electricity exported 96.4 20.4% water produced 180601 4334 Input conditions: T deg. C. P atm.
  • H2/C H2O/C CO/H2 CH4/CO HGR 1000 30 3.48 0.07 SPR 1000 30 2.47 2.91 0.21 0.93 overall energy utilization 67.2% 4 All Electric Power (AEP) MW eh/day water fed needed 260393 6249 3.1 electricity exported 4335 180.6 38.2% water produced 311110 7647 Input conditions: T deg. C. P atm.
  • H2/C H2O/C CO/H2 CH4/CO HGR 1000 30 3.48 0.07 SPR 1000 30 2.47 4.15 0.21 0.93 overall energy utilization 38.2% 5 FTL with water:biomass at 9:1 and adiabatic HGR (AHGR) bbl/day water fed used 753975 18095 9.0 synthetic diesel fuel 18147 436 3512 182.7 38.6% electricity exported 155.1 32.8% process water recovered 775890 18621 Input conditions: T deg. C. P atm. H2/C H2O/C CO/H2 CH4/CO adiabatic HGR 738 30 1.67 0.43 SPR 900 30 0.84 3.08 0.18 4.47 synthesis reactor 200 10 1.38 0.47 0.17 overall energy utilization 71.4% revision Oct.
  • AHGR adiabatic HGR

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